Dosing pump assembly

ABSTRACT

A metering pump assembly for admixing a fluid reduction agent from a supply container and a pressurized air flow into an exhaust gas flow of a combustion engine includes an assembly housing and a pre-mixer at least partially within the housing. A membrane pump within the housing is fluidly connected between the supply container and the pre-mixer. An electric motor generates a rotational output. A transmission converts the rotational output of the electric motor into translatory movement. The translatory movement drives the membrane pump to pump the reduction agent from the supply container into the pre-mixer. The pressurized air flow is in fluid communication with the pre-mixer and mixes with the reduction agent within the pre-mixer to form a reduction agent air mixture. An exit conduit fluidly connects the pre-mixer to the exhaust gas flow. The reduction air mixture is delivered through the exit conduit and into the exhaust gas flow.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/165,087 filed Jun. 23, 2005 which is a continuation of InternationalApplication No. PCT/EP2003/014664, filed Dec. 19, 2003, which waspublished in the German language on Jul. 15, 2004, under InternationalPublication No. WO 2004/059164 A1 and the disclosure of which isincorporated herein by reference.

BACKGROUND OF THE INVENTION

The invention relates to a metering pump assembly for admixing a fluidreduction agent to an exhaust gas flow, with an assembly housing whichaccommodates an electrical drive, a transmission, a membrane pump, andcontrol and regulation electronics

With auto-ignition internal combustion engines, on operation with anexcess of oxygen, which is the case in the majority of operatingconditions, nitrogen oxides arise, and specifically for example withdirect injection into the main combustion space, as is typically thecase with diesel motors. It is known to lead the exhaust gas flow to areduction catalyser in order to reduce these environmentally harmfulNO_(x) emissions. An aqueous urea solution as a reduction agent is ledto the exhaust gas in a finely distributed manner before entry into thecatalyser. At the same time the quantity of fed urea is to be matched asexactly as possible to the combustion process, in order to ensure ascomplete a reduction as possible within the catalyser and on the otherhand to avoid an excess of urea. For this purpose, separate control andregulation (closed-loop control) electronics are required which controlthe supply of urea in dependence on the variables which arecharacteristic of the combustion and reduction process (temperatureupstream and downstream of the catalyser, the air volume led to thecombustion process, NO_(x) and O₂ content of the exhaust gas).

It is known from German published patent application DE 44 36 397 A1 toapply a metering valve in order to supply the aqueous urea solution inthe quantity which is required at just this respective moment. At thesame time, the delivery of the urea solution is effected by way of theapplication of pressure to a supply tank with pressurized air, which inturn also serves for entraining the urea solution into the exhaust gasflow.

The setting of the urea supply container under pressure, in combinationwith a metering valve directly in front of the injection location, hasdisadvantages which are inherent to the system. In this respect, thatwhich is more favorable is the application of a metering pump whichsuctions the aqueous urea solution from an essentially pressure-freesupply container and leads this in a targeted manner to a pressurizedgas, in particular to a pressurized air flow which is led then via anozzle to the exhaust gas flow in a finely distributed manner directlyupstream of the catalyser. Such an arrangement is particularly preferredfor a mobile application in motor vehicles, and is known for examplefrom U.S. Pat. No. 5,842,341.

Metering pumps are applied in many technical fields, but are usuallystationary. Such a metering pump manufactured and marketed by thecompany Grundfos, Denmark is known under the type descriptions DME andDMS. These pumps are designed and conceived for stationary applicationand are therefore suitable only to a limited extent for the applicationpurpose being discussed here.

BRIEF SUMMARY OF THE INVENTION

Against this state of the art, it is the object of the present inventionto provide a metering pump assembly which is specially designed foradmixing a fluid reduction agent into an exhaust gas flow, in particularof a motor vehicle.

According to the invention, the metering pump assembly described at theoutset has an assembly housing comprising at least parts of a pre-mixerin which the fluid reduction agent is subjected to a pressurized gasflow. Advantageous embodiments of the invention are described in thefollowing description and the drawings.

The basic concept of the present invention is the provision of themetering pump assembly with further components for this specialapplication purpose, which are usefully to be arranged in the assemblyhousing. At the same time, depending on the design, only parts of thepre-mixer or this too may be arranged completely in the assemblyhousing, including the auxiliary assemblies required for this. This isparticularly advantageous for application in vehicles, where theassembly of individual components is to be avoided whenever possible,since on the one hand the components should be encapsulated from theharsh influences of the environment, on the other hand the componentsshould be mounted with low oscillation, and finally restriction orremoval of installation space for other assemblies should be allowed.

The pre-mixer which, according to the invention, is arranged at least inparts within the assembly housing serves first for subjecting the liquidreduction agent (generally an aqueous urea solution, for example a 30%urea solution) to a pressurized air flow in order then to feed thispre-mixed mass flow to the exhaust gas flow in a manner such that it isdistributed as finely as possible by way of a nozzle arranged in theexhaust gas flow directly upstream of the catalyser. At the same time,the metering pump ensures that only just that quantity of urea solutionis fed which is required for the reduction of the nitrogen oxides.

Since urea which is maintained in aqueous solution, on contact with air,thus in particular also pressurized air, may at least partly crystalliseout, which may lead to sticking, restrictions and blockages in theconduit system, according to a further formation of the invention meansfor blowing out the conduit parts coming into contact with the fluidreduction agent as well as with the pressurized gas flow are provided,thus at least for the conduit parts which lie downstream of the locationat which the two flows meet.

In order to render this possible, a first valve is arranged within theassembly housing, which in a first switch position connects a conduitleading the pressurized air flow to a conduit leading to the exhaust gasflow for the purpose of blowing out this conduit, and in a second switchposition connects the exit conduit of the pump to the conduit leading tothe exhaust gas flow, thus forms the normal operational position. Thus,without further technical accessories and while using pressurized airwhich is available in any case, one may achieve a blowing-out of thecorresponding conduit parts by way of a suitable activation of thisfirst valve, in order to protect to a large extent these conduit partsfrom urea deposits.

On the other hand, before operation of the pre-mixer it is to be ensuredthat the conduit system, in particular from the exit of the pump up tothe mixing location, is completely filled with fluid reduction agent,since only then does the admixed quantity of reduction agent correspondto the quantity delivered by the metering pump. For this purpose,according to the invention, means are provided for flushing and/orbleeding the conduits leading the reduction agent, and specificallywithin the assembly housing. In this connection, a secondvalve—hereinafter called pre-flushing valve—is arranged within theassembly housing, by which the exit conduit of the pump may beselectively connected to a conduit, which leads to the tank for thereduction agent, or to a conduit leading to the first valve or to theexhaust gas flow. The latter position is the operational position. Forthe starting operation of the pre-mixer, the pre-flushing valve iscontrolled into the first-mentioned position and the metering pump isswitched to permanent operation, so that the conduit is continuouslyflushed with liquid reduction agent, which then flows back into thesupply container. On account of this, one reliably ensures that theconduits leading the reduction agent are completely filled with theagent.

Usefully, the assembly housing is constructed of several parts which arefunctionally separated from one another, and specifically in a mannersuch that one housing part is provided for the electronics, anotherhousing part for the drive motor and the drive mechanics, and a furtherhousing part for the components leading the fluid, such as conduits,conduit connections, valves and membrane pump. At the same time, thedrive mechanics are preferably arranged in the middle housing part, andthe electronics to one side and the fluid-leading components to theother side of this middle housing part. Such an arrangement not onlyencourages the operational reliability of the assembly, but is alsoadvantageous in the case of repairs since, for example, exitingreduction agent may not come into contact with mechanical or electroniccomponents.

It is to be understood that the valves are usefully arranged in thefluid-leading part of the pump housing, just as the conduit connections,thus preferably also the connection for a pressurized air supply conduitfor the supply of the assembly with pressurized air.

Since the pressurized air conduit, particularly with vehicles, isusually under operating pressure, on the assembly side it is useful toprovide a shut-off valve for the conduit leading pressurized air, inorder to be able to shut off the supply of pressurized air whenrequired.

In order to prevent fluid reduction agent from penetrating into thepressurized air conduit, for example in the case of a pressure drop, andthis becoming possibly restricted due to the crystallisation of theurea, a return valve is usefully provided in the conduit leading thepressurized air, and specifically downstream of the shut-off valve inthe through-flow direction. This return valve usefully likewise lieswithin the assembly housing, and specifically in the housing part forthe fluid-leading parts.

In order to be able to exchange the complete assembly in a quick andsimple manner for repair or maintenance purposes, it is useful toprovide in each case a conduit connection on the assembly housing forall conduits leading fluid, the connection being envisaged for thereleasable connection to a corresponding connection conduit. This, in asimple form, may be formed by a connection spout (union) onto which aflexible tubing may be pushed, but also by flexible tubing couplingsystems. Since, preferably, digital control and regulation electronicsare present in any case within the assembly housing of the metering pumpassembly, it is useful to also arrange the control and/or regulationelectronics within the assembly housing, these electronics beingnecessary for the reduction process and the valve-control.

According to the invention, the assembly housing may also encompassparts of the pre-mixer. Thus the actual mixing procedure between theconduit leading the reduction agent and the conduit leading thepressurized air may take place outside the assembly housing, if this isadvantageous. According to a preferred formation of the invention,however, the assembly housing does not comprise the complete pre-mixer.This is not only favorable with regard to design, but also with regardto extreme operating conditions, such as at low temperatures asregularly occur in the operation of motor vehicles. One may then ensurethe operational reliability of the complete pre-mixer by way ofprovisions on the part of the assembly housing, without having to makefurther provisions on the part of the vehicle.

In order to be able to apply the metering pump assembly in vehicleswhich realize the control and/or regulation electronics for thereduction process and the valve control by way of the digital motorelectronics, as well as in those with which such control and/orregulation electronics are not provided, it is useful to provide theregulation (closed-loop control) electronics or at least parts of theregulation electronics as a housing module, which is preferablyreleasably attached, so that the metering pump assembly may be appliedwith or without such a module depending on the application purpose.

Briefly stated, the present invention is directed to a metering pumpassembly for admixing a fluid reduction agent from a supply containerand a pressurized air flow into an exhaust gas flow of a combustionengine and includes an assembly housing for mounting proximate to theexhaust gas flow. A pre-mixer has at least a portion thereof within theassembly housing. A membrane pump is within the assembly housing and isfluidly connected between the supply container and the pre-mixer. Anelectric motor is within the assembly housing and generates a rotationaloutput. A transmission converts the rotational output of the electricmotor into translatory movement. The translatory movement drives themembrane pump to pump the reduction agent from the supply container intothe pre-mixer. The pressurized air flow is in fluid communication withthe pre-mixer and mixes with the reduction agent within the pre-mixer toform a reduction agent air mixture. An exit conduit fluidly connects thepre-mixer to the exhaust gas flow. The reduction air mixture isdelivered through the exit conduit and into the exhaust gas flow.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofthe invention, will be better understood when read in conjunction withthe appended drawings. For the purpose of illustrating the invention,there are shown in the drawings embodiments which are presentlypreferred. It should be understood, however, that the invention is notlimited to the precise arrangements and instrumentalities shown. In thedrawings:

FIG. 1 is a schematic block diagram illustrating the pre-mixer with itsauxiliary assemblies, the exhaust gas conduit system and the reductioncatalyser, according to an embodiment of the invention;

FIG. 2 is a block diagram of the pre-mixer of the metering pump assemblyaccording to an embodiment of the invention; and

FIG. 3 is a metering pump assembly according to the invention in asimplified, partly sectioned, perspective view.

DETAILED DESCRIPTION OF THE INVENTION

The exhaust gas conduit 1 of a diesel motor is shown in FIG. 1, whosethrough-flow direction is indicated at 2. The warm exhaust gas comingfrom the combustion engine flows through the conduit 1 first past asensor 3, which detects the nitrogen oxide content and the oxygencontent. In the through-flow direction, a nozzle head 4 lies downstreamof this, via which a flow comprising pressurized air and fluid reductionagent in the form of aqueous urea is led to the exhaust gas flow 2 in afinely distributed manner. A reduction catalyser 5, after whose exit theexhaust gas leaves the system through the free end 6 of the conduit,connects directly downstream of this. In the flow direction, temperaturesensors 7 are provided in each case upstream and downstream of thecatalyser 5.

The nozzle head 4 is supplied by a conduit 8 which comes from a meteringpump assembly 9, as is shown by way of FIGS. 2 and 3. The metering pumpassembly 9 comprises an assembly housing 10, which is divided intoessentially three regions 11, 12, and 13. The housing part 11, whichconnects to an end-face of the housing 10 on the one hand, comprises thecontrol and regulation electronics for the metering pump as well asfurthermore the control and regulation electronics for the reductionprocess. These control and regulation electronics may be connected tothe motor electronics via a CAN-bus and furthermore detect the signalsof the temperature sensors 7, the sensor 3 and the air mass flow led tothe combustion procedure which is symbolised in FIG. 1 by the arrow 14.

A housing part 12 connects to the housing part 11 for the electronics,and this housing part 12 comprises the drive motor in the form of astepper motor 15, as well as an eccentric gear 16 which steps down therotational movement of the motor 15 and converts this into a translatorymovement, which drives the actual membrane pump 17, which is seated in ahousing part 13 connecting to the housing part 12 and comprising allfluid-leading parts of the assembly. The housing part 13 is separatedfrom the housing part 12 by way of an intermediate wall (not shown) sothat in the case of an inadvertent escape of fluid, be it on repair orwith a leakage, it is ensured that the fluid may not penetrate into thehousing parts 11 and 12.

The housing part 11 is designed in a divided manner and comprises a partwhich is integrally formed with the remaining housing 10 and whichcomprises the control and regulation electronics for the motor 5, aswell as a removable housing 11 a, which connects thereto at the end-faceand which comprises the electronics required for the control andregulation of the reduction process. In this manner, the assembly may beapplied selectively with or also without these control and regulationelectronics for the reduction process. The housing part 11 a is designedin a modular manner and is connected electrically to the remainingelectronics by way of plug-and-socket connections, and is alsoreleasably connected to the housing part 11 in a mechanical manner. Theactual membrane pump 17 with the associated return valves is locatedwithin the housing part 13. Furthermore, four connections 18 areprovided on the housing part 12 to which conduits are releasablyconnected and which are shown in detail in FIG. 2.

The membrane pump 17 as well as a pre-mixer 19 is arranged in thehousing part 13. The pre-mixer 19 comprises a first 3/2-way valve 20, asecond 3/2-way valve as a pre-flushing valve and a shut-off valve 22, aswell as a throttle location 23.

The functions and the conduit connections and the valves operate asfollows.

Before the start of the operation of the pump assembly, with thepre-mixer 19 it must be ensured that the conduit 24 on the pump exitside is filled with fluid reduction agent. For this purpose, thepre-flushing valve 21 is activated in a manner such that the conduit 24on the pump exit side is connected to a return conduit 25, which conveysthe fluid reduction agent back into a supply container 26. The reductionagent is suctioned and delivered towards the pump 17 from the supplycontainer 26.

After the flushing has been effected and it is thus ensured that theconduit 24 leads the liquid in a complete manner, the pre-flushing valve21 is changed over, by which the conduit 24 on the pump exit side isconnected to the entry of the valve 20, which in the operationalposition is connected such that a conduit connection to the conduit 8exists which feeds the nozzle head 4. Reduction agent gets into theconduit 8 via this conduit lead. Pressurized air, which is supplied viaa connection 18 and a conduit 27, goes through the opened shut-off valve22 to the throttle location 23 and from here via the mixing location 28into the conduit 8, so that with a suitable delivery of the pump 17 andimpinging of the conduit 27 with pressurized air, the desired pre-mixingis effected and is led via the conduit 8 (likewise via connection 18)out of the assembly housing.

The metering of the reduction agent is effected in a manner known perse, dependent on operation, with the help of control and regulationelectronics. On completing the operation, thus for example when theinternal combustion engine has been switched off, the valve 20 isre-routed in a manner such that the conduit 27 leading pressurized airwhile bypassing the throttle location 23 is directly connected to theconduit 8. In this manner, the part of conduits leading the reductionagent which lies on the other side of the valve 20, thus also the partwhich lies on the other side of the mixing location 28 is supplied withpressurized air, by which the reduction agent remaining in the conduitis blown out via the nozzle 4, and thus the conduit system itself maynot become contaminated by urea which crystallises out.

The four connections 18 of the housing part 13 are thus connections forthe suction conduit 29 of the pump 17, for the return conduit 25 to thesupply container 26, for the supply of pressurized air to the conduit27, and for the conduit 8.

The electrical and sensor connections are provided on the housing part11. The assembly housing is designed in a compact manner andhermetically sealed, so that it may be installed at any location in themotor space. The assembly is electrically designed for supply from thevehicle's own electricity supply, for example 12 volts or 42 volts. Thesupply container 26 for the reduction agent is non-pressurized and maytherefore be arranged at any location in the vehicle, and no specialprovisions are required, as is the case with pressurized containers. Thepressurized air which is required for operation of the pre-mixer may betaken from the vehicles own pressurized air supply or may be provided byway of a separate compressor.

It will be appreciated by those skilled in the art that changes could bemade to the embodiments described above without departing from the broadinventive concept thereof. It is understood, therefore, that thisinvention is not limited to the particular embodiments disclosed, but itis intended to cover modifications within the spirit and scope of thepresent invention as defined by the appended claims.

1. A metering pump assembly for admixing a fluid reduction agent from asupply container and a pressurized air flow into an exhaust gas flow ofa combustion engine, the metering pump assembly comprising: an assemblyhousing for mounting proximate to the exhaust gas flow, the assemblyhousing being divided into a first housing part, a second housing partand a third housing part, each housing part defining a cavity, thesecond housing part being connected to both the first and third housingparts, the first housing part includes control and regulationelectronics at least partially enclosed by the cavity thereof; apre-mixer having at least a portion thereof within the assembly housing;a membrane pump at least partially enclosed by the cavity of the thirdhousing part of the assembly housing and fluidly connected between thesupply container and the pre-mixer by a conduit, a return conduitfluidly connected between a pre-flushing valve within the pre-mixer andthe supply container; an electric motor at least partially enclosed bythe cavity of the second housing part of the assembly housing generatinga rotational output; a transmission at least partially enclosed by thecavity of the second housing part of the assembly housing converting therotational output of the electric motor into translatory movement, thetranslatory movement driving the membrane pump to pump the reductionagent from the supply container into the pre-mixer, the pressurized airflow being in fluid communication with the pre-mixer and mixing with thereduction agent within the pre-mixer to form a reduction agent airmixture; and an exit conduit fluidly connecting the pre-mixer to theexhaust gas flow, the reduction air mixture being delivered through theexit conduit and into the exhaust gas flow.
 2. The metering pumpassembly according to claim 1, wherein the assembly housing includes aconnection for a pressurized air supply conduit.
 3. The metering pumpassembly according to claim 2, wherein the assembly housing includes areturn valve downstream of the membrane pump.
 4. The metering pumpassembly according to claim 2, wherein the assembly housing includes athrottle upstream of a location at which the reduction agent issubjected to the pressurized air flow such that the throttle controlsthe delivery of the reduction agent air mixture to the exhaust air flow.5. The metering pump assembly according to claim 1, wherein the assemblyhousing further includes a valve control to control the pre-mixer. 6.The metering pump assembly according to claim 5, wherein at least partsof the control and the regulation electronics are located within ahousing module releasably attached to the assembly housing.
 7. Themetering pump assembly according to claim 6, wherein the parts of thecontrol and regulation electronics form a closed-loop control system. 8.The metering pump assembly according to claim 1, wherein means areprovided for blowing out the exit conduit.
 9. The metering pump assemblyaccording to claim 1, further including a first valve within theassembly housing, the first valve in a first switched position fluidlyconnecting the pressurized air flow to the exit conduit and the firstvalve in a second switched position connecting the membrane pump to theexit conduit.
 10. The metering pump assembly according to claim 1,wherein the return conduit fluidly connects the membrane pump downstreamof the membrane pump back to the supply container.
 11. The metering pumpassembly according to claim 1, wherein the assembly housing includes areleasable conduit connection for each fluid-leading conduit leadinginto or out of the assembly housing.
 12. The metering pump assemblyaccording to claim 1, wherein the pre-mixer is entirely within theassembly housing.
 13. The metering pump assembly according to claim 1,wherein the exit conduit includes a nozzle positioned within the exhaustair flow, the nozzle spraying the reduction agent air mixture into theexhaust air flow.